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DD15 Injector Remove-Install

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841 views7 pages

DD15 Injector Remove-Install

Uploaded by

arie
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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3.27.

4 Removal of the Fuel Injector - Two-Filter System


Remove as follows:
Note : If replacing fuel injectors, due to a no start condition after a repair, also replace the
fuel rail and all high pressure fuel lines.

WARNING
PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine
has been shut down for a minimum of 10 minutes before servicing any component within
the high pressure circuit. Residual high fuel pressure may be present within the circuit.
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been shut
down for a minimum of 10 minutes before servicing any component within the high pressure circuit.
Residual high fuel pressure may be present within the circuit.
1.
Shut off the engine and apply the parking brake, chock the wheels, disconnect vehicle battery power,
and perform any other applicable safety steps.

WARNING
FIRE HAZARD
Do not power wash or steam clean the engine bay in the area of vehicle electrical
components, unless specified by vehicle manuals or service literature. Power
washing/steam cleaning can permanently damage these components, which could result
in fire, personal injury, or property damage.
2.
Do not power wash or steam clean the engine bay in the area of vehicle electrical components,
unless specified by vehicle manuals or service literature. Power washing/steam cleaning can
permanently damage these components, which could result in fire, personal injury, or property
damage.
Steam clean the engine.
3.
Remove the rocker cover. Refer to section "Removal of the Rocker Cover" .
4.
Disconnect the 14-pin fuel injector harness connector from the camshaft housing.
5.
Disconnect the fuel injector electrical wiring harness from the fuel injectors. Refer to section "Removal
of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System" .
6.
Remove the spring clip holding the fuel injector electrical wiring harness connector to the camshaft
frame. Remove the fuel injector electrical wiring harness.
7.
Remove the high pressure fuel injector feed lines. Refer to section "Removal of the High Pressure
Fuel Injector Lines - Two-Filter System" .
8.
Remove the fuel injector hold down bolt (1). Discard bolt.
9.
Using tool J-47391 (1), lift the fuel injector clamp and fuel injector (2) from its seat in the cylinder
head.
10.
Remove clamps from the fuel injector and install a tip protector onto the fuel injector nozzle.
11.
Cover the fuel injector hole in the cylinder head to keep out foreign material.
NOTICE
Avoid cleaning (wire brushing etc.) the fuel injector tip spray holes to prevent damage and
plugging.
12.
Using a clean rag soaked with clean diesel fuel, carefully remove any carbon material from the fuel
injector exterior.
NOTICE
Fuel injector O-ring seals, fuel injector clamp bolt and the fuel injector copper washer are
considered one-use items and cannot be reused. Any time a fuel injector is removed, the
fuel injector bolt, three fuel injector O-ring seals and copper washer must be replaced with
new parts. Failure to replace the O-ring seals copper washer and bolt can result in
leakage.
13.
Inspect the fuel injector body for visible damage. Replace the fuel injector if damaged.
14.
If the fuel injector is intended to be reused, remove and discard the three fuel injector O-rings and the
copper washer.

3.27.5 Installation of the Fuel Injector - Two-Filter System


Install as follows:
Note : Ensure excess fuel is removed from the top of the piston dome before fuel injector
installation.
Note : If replacing fuel injectors, due to a no start condition after a repair, also replace the
fuel rail and all high pressure fuel lines.
1.
If the fuel system is contaminated:
Drain the fuel tanks and refill with clean fuel.
Clean the fuel water/separator and replace the fuel filters.
2.
If the coolant system is contaminated with fuel, flush and reverse-flush the system.
3.
If the oil system is contaminated, change the engine oil and filters.
NOTICE
The fuel injector tube bore should be cleaned and inspected for damage or leakage of
coolant before installation of the fuel injector.
4.
Check to make sure the fuel injector tube bore is thoroughly clean.
5.
If new or remanufactured fuel injectors are being used, write down the new (2) or remanufactured (1)
fuel injector's calibration code, the injector part number and note the cylinder location where it will be
installed.
6.
Remove the fuel injector nozzle tip protector.
NOTICE
The older-style copper washer must be installed with the recess (1) facing the fuel injector
body. Incorrect installation can cause combustion gasses to enter the fuel system.
7.
Install a new copper washer with the recess facing UP (1) toward the fuel injector and the flat side of
the washer facing DOWN. The new-style copper washer (2) is flat on both sides and does not need to
be installed with a specific side up or down.
8.
Apply a thin coat of acid-free grease or clean engine oil to the fuel injector seal rings and then use J-
48837 (Fuel Injector O-ring Installer) to install them in the fuel injector nut ring grooves. Make sure
they are properly seated.
9.
Install the fuel injector and clamp as an assembly into its respective fuel injector bore. Align the clamp
over the bolt hole, install the new bolt into fuel injector clamp and snug until the fuel injector fully
seats, then release the fuel injector bolt. DO NOT torque.
Note : If the high pressure lines leak after installation, the lines need to be replaced.
10.
Install the high pressure fuel injector feed lines. Refer to section "Installation of the High Pressure
Fuel Injector Lines - Two-Filter System" .
11.
Torque the fuel injector hold-down bolt to 20 N·m (15 lb·ft) + 90 degree torque turn.
12.
Insert the 14–pin connector from the fuel injector harness into the hole in the cam frame and install
electrical connections and Allen head hold-down bolts before torquing.
13.
Install the spring clip onto the 14–pin connector.
14.
Torque all of the fuel injector connections to 1.9 N·m (17 lb·in.).
15.
Torque all of the Allen head fuel injector harness hold-down bolts to 10 N·m (7 lb·ft).
16.
Input the fuel injector calibration codes and injector part number that were recorded earlier into
DiagnosticLink ® using the service routine.
17.
If injectors were replaced because of a tip failure or leak, the EGR cooler must be cleaned.
For DD13: Refer to section "Cleaning of the DD13 Exhaust Gas Recirculation System". Refer to
section "Cleaning of the DD13 Exhaust Gas Recirculation System"
For DD15 and DD16: Refer to section "Cleaning of the Turbo Compound DD15 and DD16 Exhaust
Gas Recirculation Systems". Refer to section "Cleaning of the Turbo Compound DD15 and DD16
Exhaust Gas Recirculation

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